Stackable and nestable container

ABSTRACT

A stackable and nestable container having a bottom, opposed first and second end walls and opposed first and second side walls extending upwardly from the bottom and collectively defining an open top. First and second bales are mounted on and extend between the first and second side walls for movement between a stacking position extending into the open top of the container and a nesting position resting on a top edge of the first end wall. First and second bale-receiving channels are formed in the bottom of the container and extend between the first and second side walls directly below the stacking position of the first and second bales and are sized and shaped to receive the first and second bales of a like container when in the stacking position to define a stack of containers.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

This invention relates to a stackable and nestable container of the type that has numerous applications in manufacturing and related shipping and commerce. This type of container is frequently used to ship parts and supplies between part and component suppliers and factories where the parts and components are incorporated into assembled products. When being shipped with contents, they are typically stacked on top of each other. To reduce the cost of shipping, this type of container is repeatedly reused, so it must be shipped back to the source, usually empty, for refilling and reshipping. For this reason, the containers are made with a side wall draft angle sufficient to permit the containers to be nested into each other when empty, a practice which dramatically increases the number of empty containers that can be accommodated in a given space. The invention of this application provides a container that maximizes the usable volume of the container.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a container that is both nestable and stackable.

It is another object of the invention to provide a container that has a minimum of separate parts that must be assembled to create the container.

It is another object of the invention to provide a container that has a unique feature that reduces or eliminates shifting of the containers when stacked.

It is therefore an object of the present invention to provide a container that maximizes the internal volume of the container.

These and other objects and advantages of the invention are achieved by providing a stackable and nestable container having a bottom, opposed first and second end walls and opposed first and second side walls extending upwardly from the bottom and collectively defining an open top. A first bale is mounted on, and extends between the first and second side walls proximate the first end wall and is movable between a stacking position extending into the open top of the container and a nesting position resting on a top edge of the first end wall. A second bale is mounted on, and extends between the first and second side walls proximate the second end wall and is movable between a stacking position extending into the open top of the container and a nesting position resting on a top edge of the second end wall. A first bale-receiving channel is formed in the bottom of the container, extending between the first and second side walls directly below the stacking position of the first bale, and sized and shaped to receive the first bale of a like container when in the stacking position to define a stack of containers. A second bale-receiving channel is formed in the bottom of the container, extending between the first and second side walls directly below the stacking position of the second bale, and sized and shaped to receive the second bale of a like container when in the stacking position to define a stack of containers. The first and second bales each include at least one outwardly-projecting tab for restricting lateral movement of a stacked like container by providing a stopping surface for first and second side walls of the like container. The first and second bale-receiving channels define respective complementary first and second ridges on the bottom of the container, extending upwardly into the container.

According to another embodiment of the invention, the first and second side walls include recessed pockets in which respective first and second bales are mounted on pivots for pivotal movement between the stacking and nesting positions.

According to another embodiment of the invention, the recessed pockets each include a base on which the respective bale rests in the stacking position.

According to another embodiment of the invention, the first and second bales each include a radially-outwardly projecting support tab for supporting the respective bale on the container in the nesting position.

According to another embodiment of the invention, the first and second end walls each include first and second recessed pockets in which respective first and second bales are received when the bales are in the nesting position.

According to another embodiment of the invention, the first and second bales are cylindrical and the first and second channels are semi-cylindrical.

According to another embodiment of the invention, the first and second bales each include a pair of radially-outwardly projecting tabs for restricting the lateral movement of a like stacked container by providing stopping surfaces for the first and second side walls of the like container.

According to another embodiment of the invention, a stackable and nestable container includes surface elements on the first and second bales and surface elements on the first and second channels that are positioned to align and mate with the surface elements of the respective first and second bales of a like container when the container is in the stacking position.

According to another embodiment of the invention, the surface elements include a plurality of parallel, spaced-apart grooves that are perpendicular to a longitudinal axis of the respective bales and channels.

According to another embodiment of the invention, the surface elements include a plurality of parallel, spaced-apart, integrally-formed grooves that are perpendicular to a longitudinal axis of the respective bales and channels.

According to another embodiment of the invention, a stackable and nestable container is provided having a bottom, opposed first and second end walls and opposed first and second side walls extending upwardly from the bottom and collectively defining an open top. A first bale is mounted on and extends between the first and second side walls proximate the first end wall and is movable between a stacking position extending into the open top of the container and a nesting position resting on a top edge of the first end wall. A second bale is mounted on and extends between the first and second side walls proximate the second end wall and is movable between a stacking position extending into the open top of the container and a nesting position resting on a top edge of the second end wall. Recessed pockets are provided in which the respective first and second bales are mounted for movement between the stacking and nesting positions and including a base on which the respective bales rest in the stacking position. A first channel is formed in the bottom of the container and extends between the first and second side walls to receive a first bale of a like container when in the stacking position to define a stack of containers. A second channel is formed in the bottom of the container and extends between the first and second side walls to receive the second bale of a like container when in the stacking position to define a stack of containers. The first and second bale-receiving channels define respective complementary first and second ridges on the bottom of the container, extending upwardly into the container. According to another embodiment of the invention, the surface elements comprise a plurality of parallel, spaced-apart, integrally-formed grooves that are perpendicular to a longitudinal axis of the respective bales and channels.

According to another embodiment of the invention, the first and second bales are pivotally mounted for movement between the stacking and nesting positions.

According to another embodiment of the invention, the first and second channels and first and second ridges are integrally formed in the bottom of the container and are opposed surfaces of first and second respective concave and convex structures.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

The present invention is best understood when the following detailed description of the invention is read with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a container according to one preferred embodiment of the invention in the nesting configuration;

FIG. 2 is a perspective view of two like containers according to FIG. 1 with the upper container nested into the lower container;

FIG. 3 is a perspective view of a container according to one preferred embodiment of the invention in the stacking configuration;

FIG. 4 is a perspective view of two of the containers of FIG. 3 in the stacking configuration;

FIG. 5 is a bottom plan view of the container showing the bottom of the container and the channels formed into the exterior wall of the container bottom;

FIG. 6 is a fragmentary perspective view showing one of the bales in the stacking position;

FIG. 7 is a fragmentary perspective view of one of the bales in the nesting position; and

FIG. 8 is a fragmentary perspective view of one of the bales in an intermediate position between the nesting position and the stacking position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIG. 1, a container 10 is shown and includes a bottom 12, opposed first and second end walls 14, 16 and opposed first and second side walls 18, 20. The end walls 14, 16 and side walls 18, 20 extend upwardly at diverging draft angles from the bottom 12 to collectively form an open top. While the end walls 14, 16 and side walls 18, 20 are shown as planar surfaces, in many instances the walls may be provided with stiffening ribs and recesses and other features that do not form part of this invention. The second end wall 16 and the second side wall 20 include respective hand holds 22, 24. The container 10 and its components maybe manufactured by any suitable fabrication process, such as molding and maybe fabricated from any suitable plastic, resin or other material.

Bales 30, 32 are each formed of cylindrical bars that are mounted on respective side walls 18, 20. Bale 30 is mounted proximate the end wall 14 on arms 34, 36 that pivot on pivot pins 38, 40. The arms 34, 36 pivot in recessed pockets 42, 44 integrally molded into the container 10. Similarly, bale 32 is mounted proximate the end wall 16 on arms 46, 48 that pivot on pivot pins 50, 52. The arms 46, 48 pivot in recessed pockets 54, 56 integrally molded into the container 10.

As shown in FIGS. 1, 3 and 4, bales 30 and 32 extend along the length of and rest on the top rim of the end walls 14 and 16, respectively, when in the nested position. Because the bales 30 and 32 are supported along their entire length, they are protected against downward deformation while in the nested position. Bales 30 and 32 also include pivot pins 38, 40, 50 and 52 protruding from arms 36, 38, 46 and 48 that are press-fitted into recessed pockets 42, 44, 54 and 56, so that the outer walls of the pockets 42, 44, 54 and 56 restrict side-to-side motion of the bales 30 and 32 in both the stacked and nested positions, and while pivoting.

Support tabs 58, 59, 60 and 61 may be provided to support the bales 30 and 32 in the nested position. However, it is considered preferable for this support to be provided by the top rim of the end walls 14 and 16, since support is provided along the entire length of the bales 30, 32 rather than just on the ends.

Bales 30, 32 include a respective pair of surface elements in the form of a series of spaced-apart grooves 62, 64 and 66, 68. The grooves 62, 64 and 66, 68 may be integrally-formed onto the bales 30, 32 during a molding process or formed by an additional step, such as by stamping or cutting. While grooves 62, 64 and 66, 68 are shown, alternative surface elements, such as complementary touch fastener elements or grooves having different orientations may be used.

Referring now to FIGS. 1 and 2, the container 10 is shown in the nesting position with the bales 30, 32 resting on the top edge of the end walls 14, 16. In this configuration, clearance is provided for a like container 10 to nest into container 10, leaving a predetermined clearance between the underside of the bottom 12 of the like container 10 and the inner surface of the container 10. The bottom 12 includes first and second elongate semi-cylindrical ridges 70, 72 that extend upwardly from the inner surface of the bottom 12. The ridges 70, 72 form a top wall of first and second channels 74, 76 molded into the underside of the bottom 12. In addition, as is best shown in FIG. 4, when in the stacked position, the containers 10 are limited in lateral shifting by the support tabs 59, 61, 58, 60 of the lower container 10, which engages the lower edge of the side walls 18 and 20.

The channels 74, 76 are provided with respective grooves 80, 82 and 84, 86 that align and mate with the grooves 62, 64 on the bale 30 and grooves 66, 68 on bale 32 when in the stacking position. The grooves 80, 82 and 84, 86 of the channels 74, 76, may be integrally formed during a molding process or formed by an additional step, such as by stamping or cutting. While the grooves 80, 82 and 84, 86 are shown, alternative surface elements, such as complementary touch fastener elements or grooves having different orientations maybe used, as well.

As shown in FIG. 4, when the containers 10 are in a stacked configuration, the bales 30, 32 of the lower container 10 reside in the channels 74, 76 of the upper container 10.

FIG. 5 illustrates the channels 74, 76 from the underside of the container 10 and further illustrates the grooves 80, 82 and 66, 68.

FIGS. 6, 7 and 8 show details of the bale 32 (like features of bale 30 not shown) and its positions in the stacking (FIG. 6), nesting (FIG. 7) and between the two positions (FIG. 8),

In the particular embodiment disclosed in this application, the containers 10 are not nested deeply enough for the first and second ridges 70, 72 of a container 10 to nest into the first and second channels 74, 76 of a like container 10 into which the container 10 is nested. However, other embodiments of the container maybe sized and structured to facilitate this function.

In contrast to many prior art containers that have flat inner bottom surfaces, the disclosure of this application is of a container 10 that has a non-flat inner bottom surface. This provides the maximum usable internal volume for the exterior size of the container. For product that is flexible, such as hoses, wire harnesses and many products with similar features, or for packing in which small, individual parts fill the volume of the container, raised ridges on the inner bottom surface of the container do not affect packing and the added volume can be effectively utilized.

A nestable and stackable container according to the invention has been described with reference to specific embodiments and examples. Various details of the invention maybe changed without departing from the scope of the invention. Furthermore, the foregoing description of the preferred embodiments of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation, the invention being defined by the claims. 

I claim:
 1. A stackable and nestable container having a bottom, opposed first and second end walls and opposed first and second side walls extending upwardly from the bottom and collectively defining an open top and further comprising: (a) a first bale mounted on and extending between the first and second side walls proximate the first end wall and movable between a stacking position extending into the open top of the container and a nesting position resting on a top edge of the first end wall; (b) a second bale mounted on and extending between the first and second side walls proximate the second end wall and movable between a stacking position extending into the open top of the container and a nesting position resting on a top edge of the second end wall; (c) a first bale-receiving channel formed in the bottom of the container, extending between the first and second side walls directly below the stacking position of the first bale and sized and shaped to receive the first bale of a like container when in the stacking position to define a stack of containers; (d) a second bale-receiving channel formed in the bottom of the container, extending between the first and second side walls directly below the stacking position of the second bale and sized and shaped to receive the second bale of a like container when in the stacking position to define a stack of containers; and (e) the first and second bale-receiving channels defining respective complementary first and second ridges on the bottom of the container, extending upwardly into the container and that are received into complementary grooves formed on the first and second bales when in the stacking position.
 2. A stackable and nestable container according to claim 1, wherein the first and second side walls include recessed pockets in which an end portion of respective first and second bales is mounted on pivots for pivotal movement between the stacking and nesting positions.
 3. A stackable and nestable container according to claim 2, wherein the recessed pockets each include a base on which the respective bale rests in the stacking position.
 4. A stackable and nestable container according to claim 3, wherein the first and second bales each include a radially-outwardly projecting support tab for restricting lateral movement of a stacked like container by providing a stopping surface for the first and second side walls.
 5. A stackable and nestable container according to claim 1, wherein the first and second end walls each include first and second recessed pockets in which an end portion of respective first and second bales is received when the bales are in the nesting position.
 6. A stackable and nestable container according to claim 1, wherein the first and second bales are cylindrical and the first and second channels are semi-cylindrical.
 7. A stackable and nestable container according to claim 1, and including: (a) surface elements on the first and second bales; and (b) surface elements on the first and second channels positioned to align and mate with the surface elements of the respective first and second bales of a like container when the container is in the stacking position.
 8. A stackable and nestable container according to claim 7, wherein the surface elements comprise a plurality of parallel, spaced-apart grooves that are perpendicular to a longitudinal axis of the respective bales and channels.
 9. A stackable and nestable container according to claim 7, wherein the surface elements comprise a plurality of parallel, spaced-apart, integrally-formed grooves that are perpendicular to a longitudinal axis of the respective bales and channels.
 10. A stackable and nestable container having a bottom, opposed first and second end walls and opposed first and second side walls extending upwardly from the bottom and collectively defining an open top and further comprising: (a) a first cylindrical bale mounted on and extending between the first and second side walls proximate the first end wall and movable between a stacking position extending into the open top of the container and a nesting position resting on a top edge of the first end wall; (b) a second cylindrical bale mounted on and extending between the first and second side walls proximate the second end wall and moveable between a stacking position extending into the open top of the container and a nesting position resting on a top edge of the second end wall; (c) recessed pockets in which the respective first and second bales are mounted for movement between the stacking and nesting positions and including a base on which the respective bales rest in the stacking position; (d) a first bale-receiving, semi-cylindrical channel formed in the bottom of the container, extending between the first and second side walls directly below the stacking position of the first bale and sized and shaped to receive the first bale of a like container when in the stacking position to define a stack of containers; (e) a second bale-receiving, semi-cylindrical channel formed in the bottom of the container, extending between the first and second side walls directly below the stacking position of the second bale and sized and shaped to receive the second bale of a like container when in the stacking position to define a stack of containers; and (f) surface elements positioned on the first and second bales and complementary surface elements positioned on the first and second channels and adapted to align and mate with the surface elements of the respective first and second bales of a like container when the container is in the stacking position.
 11. A stackable and nestable container according to claim 10, wherein the surface elements comprise a plurality of parallel, spaced-apart grooves that are perpendicular to a longitudinal axis of the respective bales and channels.
 12. A stackable and nestable container according to claim 10, wherein the surface elements comprise a plurality of parallel, spaced-apart, integrally-formed grooves that are perpendicular to a longitudinal axis of the respective bales and channels.
 13. A stackable and nestable container according to claim 10, wherein the first and second bales are mounted for pivoting movement between the stacking and nesting positions.
 14. A stackable and nestable container according to claim 10, wherein the first and second channels and first and second ridges are integrally formed in the bottom of the container and comprise opposed surfaces of first and second respective concave and convex structures. 